Implementation of information systems in manufacturing area

Ad ances in Elec ical and Elec onic Enginee ing 120 IMPLEMENTATION OF INFORMATION SYSTEMS IN MANUFACTURING AREA P. Peniak a, b) a) IT manage , IT di ision Con inen al Ma ado s. . o., T. Vanso ej 1054/45, Púcho , Slo akia b) Depa men o Con ol & In o ma ion Sys ems, Facul y o Elec ical Enginee ing, Uni e si y o Žilina, Uni e zi ná 1, 010 26 Žilina, e-mail: pe e .peniak@con i.sk Summa y Pape deals wi h new ends ega ding implemen a ion o In o ma ion sys ems as one o he mos impo an pa s o manu ac u ing in as uc u e. The main a en ion is paid o Manu ac u ing Execu ion Sys ems and Shop Floo in eg a ion ega ded om he iewpoin o hei implemen a ion, manu ac u ing unc ions and in eg a ion. 1. INTRODUCTION Indus y is mo e and mo e echnology d i en. The ollowing decade has o be he e a o IT enabling alue c ea ion. Changing om being an in e nal se ice p o ide is one o he majo asks o IT. In o ma ion Technologies ha e been conside ed as suppo unc ion which is no di ec ly in ol ed in he co e business and alue c ea ion p ocess. The success o IT is de ined by he success o he business. By ha co esponding key pe o mance indica o s (KPI) shall be used o de ine and ack unc ional and p ojec success. The e is a need o change in he app oach o implemen ing new IT- solu ions based on  speed o change,  inno a ion capabili y,  adap a ion o new p ocesses, new unc ions, new ools,  he in ensi y o usage o he p o ided so wa e,  he abili y o alue c ea ion. Co e ac i i ies and compe ence o un a comp ehensi e ope a ing model o IT ha e o be iden i ied including skills, me hods and needed p ocesses. IT akes o e mo e and mo e esponsibili y as a pa ne o i s cus ome s in he de ini ion and ope a ion o bes in class p ocess chains a easonable cos . An IT compe ence cen e a e o p o ide p oac i ely all know how, compe encies, esou ces, ools & sys ems o de ine and suppo he p ocesses needed in he co esponding business unc ions, see Figu e 1. Fig. 1 Example o IT CCs ( Compe ence Cen e) The in o ma ion sys ems ha e o suppo all he main business p ocesses which a e necessa y o unning o business and o enable company ope a ions in global en i onmen . In addi ion he manu ac u ing a ea is becoming mo e and mo e dependen on IT. IT is esponsible no only o alue c ea ion and suppo manu ac u ing p ocesses bu mus ake in o conside a ion high a ailabili y and necessi y o con inual p oduc ion ope a ions. Any majo ail o IT could lead immedia ely o s opping o p oduc ion and his aspec is mo ing posi ion o IT o he one o mos impo an pa o manu ac u ing in as uc u e. The e o e an app op ia e implemen a ion o In o ma ion sys ems is one o he key ac o s o business success in manu ac u ing a ea. 2. INFORMATION SYSTEMS FOR MANUFACTURING Manu ac u ing as a pa o o e all en e p ise o local company mus be in eg a ed in o gene al business p ocesses ha a e suppo ed by ERP (En e p ise Resou ce Planning) In o ma ion Sys em. ERP is an indus y e m o in eg a ed, mul i-module applica ion so wa e packages ha a e designed o p o ide in o ma ion sys em o mul iple business unc ions as o de en y, gene al ledge , pu chasing, wa ehousing, anspo a ion, human esou ces and manu ac u ing. Wi h help o ERP companies can s anda dize business p ocesses and each easily he bes p ac ices. In addi ion ERP sys em has o p o ide basic ame o manu ac u ing suppo including  budge managemen ,  a icle calcula ion,  p oduc speci ica ions,  Bill o Ma e ials (BOM),  basic ou ings o p oduc s ia machine chains,  main enance me hods, and  quali y sys em de ini ion. ERP sys ems a e ypical ansac ion o ien ed sys ems whe e one business unc ion consis s o se e al IT ope a ions logically bound o a ansac ion. ERP sys ems a e ocused on ansac ions whose ime scope is de ined acco ding o epo ed pe iod such as mon hs, days, shi s leading up o minu es. CC Manu ac u ing CC Ma ke ing & Sales CC R & D CC Supply Chain Managemen CC Manu ac u ing CC Ma ke ing & Sales CC R & D CC Supply Chain Managemen Implemen a ion o in o ma ion sys ems in manu ac u ing a ea 121 The di e en app oach has o be aken in manu ac u ing a ea. IS sys ems do no only p o ide in o ma ion o con ol o p oduc ion acco ding o es ablished ules, hey ha e o be also designed o cap u e eal- ime da a as i is c ea ed, and help manu ac u e s ake ac ion in he momen , based on ha in o ma ion. The plan loo (so called ShopFloo ) needs a e unique and equi e an "ac i e" sys em ha p o ides immedia e de ec ion and no i ica ion o any non-con o mance e en wi h ala ming. P oduc ion manage s equi e a sys em ha will manage a iances, p oblem inspec ion and esolu ion, and con inuous imp o emen p ocesses while en o cing p oduc ion ules, ope a o ce i ica ions, and co ec i e ac ions. The ime ac o mus be adjus ed acco dingly and should be close o eal- ime esponse [in seconds]. The di ec applica ion o ansac ional ERP sys ems o men ioned se ices in manu ac u ing a ea is no easily managed and b ings a lo o conce ns. The e was a need o speci ic unc ions and IT se ices ha could no be co e ed only by ERP. The e o e he e was a need o in oduce middle-laye so called MES (Manu ac u ing Execu ion Sys ems) o p o ide a b idge among En e p ise sys ems (e.g. ERP sys ems such as SAP, PeopleSo ), and he au oma ion sys ems con olling manu ac u ing on he plan loo (Machine Con ol). This sys em shall also sol e he ime ac o issue ans o ming ime o ope a ions be ween ansac ions o ERP sys ems and eal- ime communica ion ha is equi ed by machine con ol sys ems. The p oposed py amid a chi ec u e o in o ma ion sys ems including ime ac o is shown in Figu e 2. The de ailed block diag am o unc ions ha a e p o ided by ERP, MES and in eg a ion laye o manu ac u ing is desc ibed in Figu e 3. Fig. 2 Py amid a chi ec u e o manu ac u ing IS MES sys ems shall p o ide he ollowing unc ions o manu ac u ing:  Dispa ching o manu ac u ing p ocesses in ShopFloo and ope a o ins uc ions.  Comp ehensi e, accu a e and imely p oduc ion and in en o y da a.  Elimina ed manual eco d keeping, imp o ing he accu acy and o ganiza ion o he da a on he shop loo .  P o ided ull p oduc aceabili y and genealogy co ela ing wo k o de s (BoM, Recipes) wi h p ocess da a.  In eg a ed quali y, p ocess da a collec ion and quali y analysis (quali y p ocesses).  Repo ing unc ions like summa ies, u iliza ion, down ime, p oduc yields, sc ap, in en o y and p oduc ion con ol (on-line epo ing). ERP MES & ShopFloo In eg a ion Machine Con ol (Au oma ion) ERP [ > 1 min ] [ < 20ms] [  1 s] En e p ise Resou ce P la nnin g Shop loo H is o ia n R ea l T im e unc ion s O pe a o In e ace I/O c om m u nic a ion s B a ch con o l P oc e ss & M a ch ine Dia gnos ics P ocess co n o l R esou ce Allo ca io n A ic le calc ula io n Dispa c h ing Onlin e epo ing F ull P od uc T a ca bili y D a a A cq uis i io n SP C Op e a o ins uc io ns M a s e D a a Re c ipe s / BO M / R ou in gs Bas ics Sch eduling & Se qu e ncing M ain en ance P o ce sses Qu a li y P oc es ses Bu dg e M g . Plannin g Q ua li y S ys em s D e ini ion M ain en a nce M e h ods Re cipes / BO M / Rou in gs P od uc ion ER P In eg a ion La ye M anu ac u ing Execu ion En e p ise R esou ce Pla nnin g Shop loo H is o ia n R eal T im e unc ion s O pe a o In e ace I/O c om m u nic a ion s B a ch con o l P oc e ss & M a ch ine Dia gnos ics P ocess co n o l R esou ce Allo ca io n A ic le calc ula io n Dispa c h ing Onlin e epo ing F ull P od uc T a ca bili y D a a A cq uis i io n SP C Op e a o ins uc io ns M a s e D a a Re c ipe s / BO M / R ou in gs Bas ics Sch eduling & Se qu e ncing M ain en ance P o ce sses Qu a li y P oc es ses Bu dg e M g . Plannin g Q ua li y S ys em s D e ini ion M ain en a nce M e h ods Re cipes / BO M / Rou in gs P od uc ion ER P In eg a ion La ye M anu ac u ing Execu ion Fig.3 Block diag am o Manu ac u ing IS unc ions Ad ances in Elec ical and Elec onic Enginee ing 122 The e is also an In eg a ion laye ha c ea es logical link among MES and he con ol sys ems in ShopFloo . This laye mus in eg a e a ious sys ems in o one common subsys em which p o ides in o ma ion necessa y o manu ac u ing p ocesses such as  I/O communica ions,  eal- ime unc ions,  da a acquisi ion,  p ocess con ol and ba ch con ol,  ope a o in e ace (HMI), and  machine diagnos ics. The ShopFloo con ol sys ems (PLCs, machine PCs, Indus ial PCs, con ol applica ions) a e connec ed o na i e indus ial ne wo ks o ins ance ieldbus echnologies like P o ibus, De iceNe , CAN o Indus ial E he ne . Fo in eg a ion wi h MES he e a e special ga eways used ins ead o a di ec communica ion. The e a e many ways how o in eg a e MES h ough he ga eways wi h con ol sys ems in ShopFloo ins ead o di ec communica ion. The o me solu ion was based mainly on he in e na ional s anda d MAP/ISO and he p o ocol MMS (Manu ac u ing Message Speci ica ion) ha used i ual de ice model o each manu ac u ing de ice and in oduced mapping o physical elemen s o any indus ial de ice o logical a iables (Va 1..Va 3) ha a e accessible ia ne wo k see Figu e 4. By using di e en ne wo ks a ga eway has o suppo se e al d i e s o each applied indus ial ne wo k p o ocol (Fig. 4a) o he e has o be used any open solu ion suppo ed by all de ices o example DDE (Fig. 4b). Fig.4 Ga eway as In eg a ion laye o MES Nowadays s anda d OPC is widely accep able in he a ea o indus ial in eg a ion, which is used o in eg a ion pu poses and as open model o communica ion. We can ind he ollowing me hods o implemen a ion o ga eways  OPC (Objec Link Embeging o P ocess Con ol)  DDE (Dynamic Da a Exchange)  DCOM (Dis ibu ed COM) OPC is being used ins ead o MMS as de ac o s anda d o indus ial in eg a ion o con ol and ieldbus sys ems wi h any kind o hos sys em o complex in o ma ion sys em like MES o ins ance p oduc wi h OPC Se e o machines di ec ly suppo ing OPC and OPC p oxy o de ices wi hou OPC suppo , see Figu e 5. Fig.5 MES OSI wi h OPC in eg a ion laye 3. IMPLEMENTATIONS OF IS IN MANUFACTURING AREA The implemen a ion o in o ma ion sys ems in manu ac u ing a ea and Shop Floo equi es he speci ic condi ions and building blocks (see Figu e 6) in o de o suppo eal- ime p ocesses and machine con ol. MES sys ems mus be a ailable in eal ime so ha machine con ol le el could ge necessa y in o ma ion o p oduc ion con ol, ecipe managemen e c. The e o e MES sys ems a e o be implemen ed in local DPCs in con as o ERP sys ems which can be hos ed in cen al DPCs and accessed ia WAN. The las decade was signi ican ly in luenced by in oduc ion o he new echnologies, p o ocols and s anda ds ha causes a majo change in IT indus y. We can summa ize hem as ollows:  Consolida ion o ha dwa e in as uc u e (Clus e s, SAN, G ids,...) wi h ocus on a ailabili y, eliabili y and o e all suppo o ope a ions,  Applica ion o da abase echnologies (SQL) wi h eal- ime suppo and ail-sa e echniques,  Using o open s anda ds o in e acing o di e en p oduc s and solu ions (OPC, XML,...),  In oduc ion o e ec i e IT ope a ions and p ocesses ( igh sou cing, ITIL/ITSM),  Consolida ion o DPCs (Da a P ocessing Cen e) in o de o educe complexi y and o p o ide eliable in as uc u e o ERP sys ems and MES,  Using o communica ion echnologies wi h suppo o SLA (Se ice Le el Ag eemen ),  T acking o ma e ial low wi h using ba codes and RFID (Radio F equency Iden i ica ion). SAP OPC Se e OPC OSI ODBC Machine Con ol OSI P ocess Book OSI OPC Clien Fac o y Floo In e ace Machine Con ol In ellu ion PP:PI In ellu ion SAPODA Implemen a ion o in o ma ion sys ems in manu ac u ing a ea 123 The example o IS implemen a ion in manu ac u ing is shown in Figu e 7. ERP sys em (SAP) is implemen ed in cen al DPC wi h using o he clus e echnologies and SNA (S o age A ea Ne wo k). ERP is connec ed wi h se e al plan s ia WAN. Local DPCs o plan s hos local MES ha a e connec ed ia OPC/ indus ial E he ne o ia speci ic ga eways wi h machine con ol laye and ieldbus. Fig. 7 Example o IS implemen a ion o manu ac u ing 4. CONCLUSION In o ma ion sys ems a e one o he mos impo an pa s o manu ac u ing in as uc u e. They mus be implemen ed in an app op ia e way o secu e and enable necessa y p ocesses and allow alue c ea ion. They will ha e o coope a e mo e and mo e wi h con ol sys ems in ShopFloo and missing unc ions and se ices in s anda d ERP sys ems will ha e o be comple ed by using MES. MES will be a key elemen in in eg a ion wi h machine con ol and will be implemen ed in local DPC in con as o ERP sys em. As well ieldbus and con ol le el will be d i en o open communica ion and se ices wi h IS ia open and accep ed s anda ds such as OPC. REFERENCES [1] DAVENPORT, T. H.: Mission c i ical: ealizing he p omise o en e p ise sys ems. Bos on, Mass. Ha a d Business School P ess; 2000, ISBN 0875849067 [2] MAHALIK, N. P.: Fieldbus echnology, Indus ial ne wo k s anda d o Real – Time Dis ibu ed Con ol, Sp inge , 2003 [3] ARC Ad iso y G oup: Manu ac u ing execu ion sys ems also equi ed o ex end he alue o an ERP sys em, San Jose, CA – Feb ua y 17, 2005 GATEW Cen al DPC WAN SAN ERP MES Local DPC Plan 1 ShopFloo Local DPC Plan n Middlewa e Componen s In eg a ion le el Da a- managemen IT Pla o ms Se e s Desk ops Comm Se ices Comm.. P o ocols & in . Ne wo k In as uc u e Thin clien s wi h Windows WP, Linux,…. HW RISC/Win el (Clus e s, Blades, SANs), SW OS (UNIX, WINTEL) OPC, WebSphe e, BS a ,….. SQL DB, XML, Da aWa ehouses, OLAPs TCP-IP, Secu e DHCP, DNS E he ne ( 10/100 Mbi and Gigabi , 10G), WLANs(802.11x)|, WANs (MPLS) G oupWa e, Email , LDAP, ADS… Secu i y MES, MMS/OPC/DDE ga eways P o ibus, De ice/Con ol Ne , E he ne IP(CIP), MMS….. Fi ewalls, An i i us p o ec ion, VPN/VLAN wi h IPSec Au oma ion MACHINE CONTROL MES/ERP Middlewa e Componen s In eg a ion le el Da a- managemen IT Pla o ms Se e s Desk ops Comm Se ices Comm.. P o ocols & in . Ne wo k In as uc u e Thin clien s wi h Windows WP, Linux,…. HW RISC/Win el (Clus e s, Blades, SANs), SW OS (UNIX, WINTEL) OPC, WebSphe e, BS a ,….. SQL DB, XML, Da aWa ehouses, OLAPs TCP-IP, Secu e DHCP, DNS E he ne ( 10/100 Mbi and Gigabi , 10G), WLANs(802.11x)|, WANs (MPLS) G oupWa e, Email , LDAP, ADS… Secu i y MES, MMS/OPC/DDE ga eways P o ibus, De ice/Con ol Ne , E he ne IP(CIP), MMS….. Fi ewalls, An i i us p o ec ion, VPN/VLAN wi h IPSec Au oma ion MACHINE CONTROL MES/ERP Fig. 6 Building block o ERP and MES o manu ac u ing